Telsonic's compact ultrasonic modules stay at the front

The final assembly machine, designed and built by the supplier, with process expertise and support from Telsonic UK, is used to produce two different variants of a front grille module.

Depending upon the variant being produced, there are either 12 or 18 individual weld points. To help keep the machine compact, and to enable easy operator access for loading and unloading, all of the weld heads are inverted and operate from within the machine base framework. The ultrasonic welding technology is based on Telsonic's AC350 integrated actuator units, recognised as reliable power systems with high levels of repeatability and a long service life. One particular feature of the AC350 integrated actuator is its compact design that allows installation in small spaces and makes it possible to achieve multiple welds in close proximity, as is the case in this application.

Each of the air-cooled welding heads uses a Titanium staking tip and can be controlled individually via the machine PLC for pressure, amplitude and weld delivery time. The AC actuator units are in turn powered by a total of 12 Telsonic MAG W035012-E 35kHz generators, which are panel mounted and complemented by Telsonic solid state switch boxes.

Telsonic engineers were involved from the earliest stages of the project, undertaking trials to develop and optimise weld process parameters and cycle time. The recently commissioned machine is now in full production at the supplier's premises.

For more information about Telsonic's AC350 integrated actuator units and other products and services, please visit www.telsonic.com.